Contents Section: Procedures All sections

Maintenance Information Volkswagen Fox G1

Procedures 8 illustrations ~1788 words

VIN LOCATION

The Vehicle Identification Number (VIN) is located on the left side of the dash panel at the base of the windshield. The VIN chart explains the code characters.

VIN CODE ID EXPLANATION

Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label. See VIN example below.

VIN Code ID Explanation. Scheme 2

Scheme 2: VIN Code ID Explanation

SEVERE & NORMAL SERVICE DEFINITIONS

Note. Use the Severe Service schedule if the vehicle to be serviced is operated under ANY (one or more) of these conditions

Service is recommended at mileage intervals based on vehicle operation. Service schedules are based on the following primary operating conditions

Normal Service

  1. Driven More Than 10 Miles Daily
  2. No Operating Conditions From Severe Service Schedule

Severe Service (Unique Driving Conditions)

  1. Short Trips In Freezing Temperatures
  2. Towing Or Heavily Loaded
  3. Severe Dust Conditions
  4. Hot Weather, Stop-And-Go Driving
  5. Extensive Idling

CAMSHAFT TIMING BELT

CAUTIONFailure to replace a faulty camshaft timing belt may result in serious engine damage.

The condition of camshaft drive belts should always be checked on vehicles which have more than 50,000 miles. Although some manufacturers do not recommend belt replacement at a specified mileage, others require it at 60,000-100,000 miles. A camshaft drive belt failure may cause extensive damage to internal engine components on most engines, although some designs do not allow piston-to-valve contact. These designs are often called "Free Wheeling".

Many manufacturers changed their maintenance and warranty schedules in the mid-1980's to reflect timing belt inspection and/or replacement at 50,000-60,000 miles. Most service interval schedules in this manual reflect these changes.

Belts or components should be inspected and replaced if any of the following conditions exist

  1. Cracks Or Tears In Belt Surface
  2. Missing, Damaged, Cracked Or Rounded Teeth
  3. Oil Contamination
  4. Damaged Or Faulty Tensioners
  5. Incorrect Tension Adjustment

Inspect timing belt at 20,000 mile intervals. Replace belt as necessary.

Scheme 3

Scheme 3: SERVICE POINT LOCATIONS

Scheme 4

Scheme 4: CAMSHAFT TIMING BELT SERVICE

Note. For more information on camshaft timing belt service refer to the 1.8L 4-CYL 8-VALVE & 2.0L 4-CYL 8-VALVE & 16-VALVE article in the ENGINE MECHANICAL section.

Scheme 5

Scheme 5: RETRIEVING FAULT CODES

Note. For more information regarding self-diagnostics refer to the TESTS W/CODES article in the ENGINE PERFORMANCE section.

Scheme 6

Scheme 6: RESETTING OXYGEN SENSOR MILEAGE COUNTER - 1987 MODELS

Note. For more information resetting service reminders refer to the MAINTENANCE REMINDER LIGHT RESET PROCEDURES article in the MAINTENANCE section.

Scheme 7

Scheme 7: JACKING & HOISTING POINTS

Scheme 8

Scheme 8: INFORMATION LABEL LOCATIONS

SERVICE LABOR TIMES

Note. For 1990 and newer vehicles, labor times are provided, where available, within appropriate SERVICE INTERVAL table in SCHEDULED SERVICES article.

WHEEL & TIRE SPECIFICATIONS

Wheel and tire sizes vary according to vehicle and equipment and can be found on the tire information label on each vehicle. Wheel and tire specifications and tire inflation pressures are listed on a label found on the right door post for 2-door vehicles and the right rear door post on 4-door vehicles.

Note. Snow chains must be used on drive wheels, in pairs only.

WHEEL TIGHTENING

Tighten all wheel lugs to 80 ft. lbs. (110 N.m).

BATTERY SPECIFICATIONS

CAUTIONWhen battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure. See COMPUTER RELEARN PROCEDURES article in the GENERAL INFORMATION section.

All models use BCI group 42 batteries with cold crank rating of 360 amps.

AIR CONDITIONING SERVICING (1993)

CAUTIONAvoid breathing R-134a refrigerant and PAG lubricant vapors, exposure may irritate eyes, nose and throat. To remove R-134a from system use R-134a recycling equipment that meets SAE J2210 specifications. If accidental system discharge occurs, ventilate work area before resuming service.
WARNINGR-134a service equipment or vehicle A/C systems SHOULD NOT be pressure tested or leak tested with compressed air. Some mixtures of air/R134a have shown to be combustible at elevated pressures. These mixtures are dangerous and may cause fire and/or explosions. See AIR CONDITIONING SERVICE article in GENERAL INFORMATION section.

ANTI-LOCK BRAKE SYSTEM

The anti-lock brake system contains electronic equipment that can be susceptible to interference caused by improperly installed or high output radio transmitting equipment. Since this interference could cause the possible loss of the anti-lock braking capability, such equipment should be installed by qualified professionals.

On models equipped with anti-lock brake systems, ALWAYS observe the following cautions

  1. DO NOT attempt to bleed hydraulic system without first referring to the appropriate ANTI-LOCK BRAKE SYSTEM article in the BRAKES Section.
  2. DO NOT mix tire sizes. As long as tires remain close to the original diameter, increasing the width is acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.
  3. Use ONLY recommended brake fluids. DO NOT use silicone brake fluids in an ABS-equipped vehicle.

BATTERY WARNING

WARNINGWhen battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION section.

REPLACING BLOWN FUSES

CAUTIONBefore replacing a blown fuse, remove ignition key, turn off all lights and accessories to avoid damaging the electrical system. Be sure to use fuse with the correct indicated amperage rating. The use of an incorrect amperage rating fuse may result in a dangerous electrical system overload.

BRAKE PAD REPLACEMENT

WARNINGUse caution when checking and/or changing brake pads, some pads may contain asbestos which can irritate eyes and may cause other health hazards. A water based solution should be used to clean brake dust from wheel and brake components. DO NOT use compressed air to blow off brake dust.

BRAKE SYSTEM

CAUTIONIf brake warning light comes on while driving it indicates a low fluid level or failure in one of the braking circuits. If the brake pedal can be depressed further than normal it is an indication that one of the brake circuits is not functioning. Stop vehicle and check brake reservoir fluid level. If level is below MIN mark, DO NOT drive vehicle. Have it towed to a repair shop. If level is between the MIN and MAX marks, proceed cautiously to a repair shop.

BRAKE PAD WEAR INDICATOR

CAUTIONIndicator will cause a squealing or scraping noise, warning that brake pads need replacement.

BRAKE PEDAL PRESSURE WITH ENGINE NOT RUNNING

CAUTIONBrake pedal requires extreme pressure to stop the vehicle when the engine is not running.

CATALYTIC CONVERTER

CAUTIONContinued operation of vehicle with a severe malfunction could cause converter to overheat, resulting in possible damage to converter and vehicle.
CAUTIONAny modification to the exhaust system on turbo models, which reduces exhaust backpressure, will lead to lean fuel mixtures and excessive spark advance. This could cause serious engine damage.

COOLANT (PHOSPHATE-FREE FORMULATIONS)

CAUTIONOnly a phosphate-free product should be used to replace the factory coolant, damage to water jacket sealing surfaces and cause cooling system corrosion. To avoid possible damage to vehicle use only phosphate-free ethylene-glycol based coolants with a mixture ratio from 44-68% anti-freeze. DO NOT use 100% anti-freeze as it will cause the formation of cooling system deposits. This results in coolant temperatures of over 300° F (149°C) which can melt plastics. 100% anti-freeze has a freeze point of only 8° F (-22°C).

COOLANT (PROPYLENE-GLYCOL FORMULATIONS)

To avoid possible damage to vehicle use only ethylene-glycol based coolants with a mixture ratio from 44-68% anti-freeze. DO NOT use 100% anti-freeze as it will cause the formation of cooling system deposits. This results in coolant temperatures of over 300° F (149°C) which can melt plastics. 100% anti-freeze has a freeze point of only -8° F (-22°C).

CAUTIONPropylene-Glycol Mixtures has a smaller temperature range than Ethylene-Glycol. The temperature range (freeze-boil) of a 50/50 Anti-Freeze/Water Mix is as follows: Propylene-Glycol -26° F (-32°C) - 257° F (125°C) Ethylene-Glycol -35° F (-37°C) - 263° F (128°C)
CAUTIONPropylene-Glycol/Ethylene-Glycol Mixtures can cause the destabilization of various corrosion inhibitors. Also Propylene-Glycol/Ethylene-Glycol has a different specific gravity than Ethylene-Glycol coolant, which will result in inaccurate freeze point calculations.

ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS

WARNINGMany solid state electrical components can be damaged by static electricity (ESD). Some will display a warning label, but many will not. Discharge personal static electricity by touching a metal ground point on the vehicle prior to servicing any ESD sensitive component.

ELECTRIC SHOCK HAZARD

WARNINGContact with live components of ignition system while engine is running could lead to a fatal electric shock.

ENGINE OIL

CAUTIONNever use non-detergent or straight mineral oil.

FUEL SYSTEM SERVICE

WARNINGRelieve fuel system pressure prior to servicing any fuel system component (fuel injection models).

HALOGEN BULBS

Halogen bulbs contain pressurized gas which may explode if overheated. DO NOT touch glass portion of bulb with bare hands. Eye protection should be worn when handling or working around halogen bulbs.

RADIATOR CAP

CAUTIONAlways disconnect the fan motor when working near the radiator fan. The fan is temperature controlled and could start at any time even when the ignition key is in the OFF position. DO NOT loosen or remove radiator cap when cooling system is hot.

RADIATOR FAN

WARNINGKeep hands away from radiator fan. Fan is controlled by a thermostatic switch which may come on or run for up to 15 minutes even after engine is turned off.

WHEELS & TIRES

Only wheels tested and approved by the manufacturer should be used on models equipped with Air Dam aerodynamic components.

WARRANTY INFORMATION

CAUTIONDue to the different warranties offered in various regions and the variety of after-market extended warranties available, please refer to the warranty package that came with the vehicle to verify all warranty options.

BASIC NEW CAR WARRANTY

The manufacturer warrants that every vehicle imported and sold as a new vehicle to a retail customer will be free of defects in material and workmanship for 2 years or 24,000 miles, whichever comes first, after the date of delivery to the first retail customer, or after the vehicle was first placed in service.

LIMITED POWER TRAIN WARRANTY

Covers the engine, transmission and drivetrain for a period of 5 years or 50,000 miles, whichever occurs first.

ANTI-CORROSION

Covers holes caused by corrosion in body sheet metal for 6 years, without respect to mileage, so long as the inspection and maintenance services are performed.

EMISSION CONTROL SYSTEM (ALL MODELS)

Manufacturer warrants that this vehicle is designed, built, and equipped so as to conform at the time of sale with all U.S. and California Air Resources Board emission regulations applicable at the time of manufacture and that this vehicle is free from defects in materials and workmanship which cause it to fail to conform with applicable regulations within the first 5 years or 50,000 miles, whichever occurs first.

EMISSION CONTROL SYSTEM (CALIFORNIA ONLY)

Vehicles are warranted against failure to conform with applicable standards for 3 years or 50,000 miles, whichever occurs first, under the Performance Warranty. The warranty covers defective emission-related parts for 7 years or 70,000 miles, whichever occurs first.

FUSES & CIRCUIT BREAKERS

The fuse panel is located under the left side of the dash board by the driver's knee.

Note. On all models, fuse specifications are listed on inside of panel cover.

Scheme 9

Scheme 9: FUSE PANEL IDENTIFICATION

Fuse & Circuit Breaker Identification

  1. 1 - Spare
  2. 2 - 15 Amp (Blue) Emergency Flasher
  3. 3 - 25 Amp (Clear) Horn, Brake Lights
  4. 4 - 15 Amp (Blue) Clock, Luggage Lights, Interior Lights, Radio
  5. 5 - 30 Amp (Green) Radiator Cooling Fan (with A/C)
  6. 6 - 3 Amp (Violet) Right Tail Light & Side Marker Light
  7. 7 - 3 Amp (Violet) Left Tail Light & Side Marker Light
  8. 8 - 10 Amp (Red) Right Headlight High Beam & High Beam Indicator
  9. 9 - 10 Amp (Red) Left Headlight High Beam
  10. 10 - 10 Amp (Red) Left Headlight Low Beam
  11. 11 - 10 Amp (Red) Right Headlight Low Beam
  12. 12 - 10 Amp (Red) Back-Up Lights, Turn Signals
  13. 13 - 15 Amp (Blue) Fuel Pump, Auxiliary Air Regulator
  14. 14 - 3 Amp (Violet) License Light, Glove Box Light
  15. 15 - 25 Amp (Clear) Windshield Wiper/Washer, Rear Wiper
  16. 16 - 30 Amp (Green) Rear Window Defroster
  17. 17 - 25 Amp (Clear) Fresh Air Fan (w/o A/C)
  18. 18 - 15 Amp (Blue) Cigarette Lighter, Rear Window Wiper (Wagon)
  19. 19 - 25 Amp (Clear) Radiator Cooling Fan (w/o A/C)
  20. 20 - 30 Amp (Green) Fresh Air Fan (with A/C)
  21. 21 - 30 Amp (Green) Radiator Cooling Fan (with A/C)
  22. 22 - Spare
  23. 23 - 10 Amp (Red) Oxygen Sensor, Idle Stabilizer, Seat Belt Warning
  24. 24 - 10 Amp (Red) Instrument Panel Lights
  25. 25 - 10 Amp (Red) Reading Lamps
  26. 26 - Spare
  27. 27 - Spare
  28. 28 - Spare
  29. 29 - Spare
  30. 30 - Spare
  31. 31 - Spare
  32. 32 - Spare

Relay & Circuit Breaker Identification

  1. 1 - Not Used
  2. 2 - Radiator Cooling Fan Relay
  3. 3 - Upshift Control Unit
  4. 4 - Not Used
  5. 5 - Load Reduction Relay
  6. 6 - Rear Wiper Relay (Wagon)
  7. 7 - Horn Relay
  8. 8 - Starter Motor Bridge Wire Relay
  9. 9 - Washer/Wiper Intermittent Relay
  10. 10 - Fuel Pump Relay
  11. 11 - Turn Signal/Emergency Flasher Relay
  12. 12 - Seat Belt Warning Relay
  13. 13 - Idle Stabilizer Control Unit
  14. 14 - A/C Relay
  15. 15 - Not Used
  16. 16 - Not Used
  17. 17 - Not Used
  1. 1 - Spare
  2. 2 - 15 Amp (Blue) Emergency Flasher
  3. 3 - 25 Amp (Clear) Horn, Brake Lights
  4. 4 - 5 Amp (Blue) Clock, Luggage Lights, Interior Lights, Radio, Vanity Mirror
  5. 5 - 30 Amp (Green) Radiator Cooling Fan (with A/C)
  6. 6 - 3 Amp (Violet) Right Tail Light & Side Marker Light
  7. 7 - 3 Amp (Violet) Left Tail Light & Side Marker Light
  8. 8 - 10 Amp (Red) Right Headlight High Beam & High Beam Indicator
  9. 9 - 10 Amp (Red) Left Headlight High Beam
  10. 10 - 10 Amp (Red) Right Headlight Low Beam
  11. 11 - 10 Amp (Red) Left Headlight Low Beam
  12. 12 - 10 Amp (Red) Back-Up Lights, Turn Signals, Instrument Warning Lights (1989 and Later)
  13. 13 - 15 Amp (Blue) Fuel Pump, Auxiliary Air Regulator, Oxygen Sensor Heater 1989 and Later)
  14. 14 - 3 Amp (Violet) License Light, Glove Box Light
  15. 15 - 25 Amp (Clear) Windshield Wiper/Washer, Rear Window Wiper (Wagon)
  16. 16 - 30 Amp (Green) Rear Window Defroster
  17. 17 - 25 Amp (Clear) Fresh Air Fan (w/o A/C)
  18. 18 - 15 Amp (Blue) Cigarette Lighter, Rear Washer Wiper (Wagon)
  19. 19 - 25 Amp (Clear) Radiator Cooling Fan (w/o A/C)
  20. 20 - 30 Amp (Green) Fresh Air Fan (with A/C)
  21. 21 - 30 Amp (Green) Radiator Cooling Fan (with A/C)
  22. 22 - Spare
  23. 23 - 5 Amp (Red) Oxygen Sensor Control Unit (Except CIS), Idle Stabilizer Control Unit, Seat Belt Warning Relay, Digifant Only: Digifant Control Unit Relay, Idle Boost Control Unit, Idle Speed Boost Valve
  24. 24 - 3 Amp (Red) Instrument Panel Lights, Heater Control Lights
  25. 25 - 5 Amp (Red) Reading Lamps
  26. 26 - Spare
  27. 27 - Spare
  28. 28 - Spare
  1. 1 - Not Used
  2. 2 - Radiator Cooling Fan Relay
  3. 3 - Not Used
  4. 4 - Not Used
  5. 5 - Load Reduction Relay
  6. 6 - Rear Wiper Relay (Wagon)
  7. 7 - Horn Relay
  8. 8 - Starter Motor Bridge Wire/Starter Interlock Relay
  9. 9 - Washer/Wiper Intermittent Relay
  10. 10 - Fuel Pump Relay
  11. 11 - Turn Signal/Emergency Flasher Relay
  12. 12 - Seat Belt Warning Relay
  13. 13 - Not Used
  14. 14 - Idle Stabilizer Control Unit
  15. 15 - A/C Relay
  16. 16 - Not Used
  17. 17 - Not Used